biofuels basics: harvesting, handling and storage
TRANSCRIPT
Biofuels Basics: Harvesting, Handling
and StorageWhat’s Up?
Biofuels Basics: Harvesting, Handling
and StorageWhat’s Up?
Carol Jones, Ph.D.Stored Product EngineerBiosystems and Ag Engineering
SPREC – Okla. State University
Top World Oil Producing & Consuming Countries, 2006
Producers
12
11
10
9
8
7
6
5
4
3
2
1
Rank
3.02.6Nigeria
3.02.7Kuwait
3.02.8Venezuela
3.02.8Un. Arab Em.
3.63.0Norway
3.73.1Canada
4.43.8China
4.53.8Mexico
4.94.2Iran
9.98.3U.S.
11.29.7Russia
13.110.7Saudi Arabia
PercentMM bpd
Country
DOE EIA, 08/08
Consumers
12
11
10
9
8
7
6
5
4
3
2
1
Rank
2.42.0Saudi Arabia
2.42.0France
2.52.1Mexico
2.62.2South Korea
2.62.2Brazil
2.72.3Canada
3.12.6India
3.12.5Germany
3.42.8Russia
6.45.2Japan
8.27.2China
24.620.7U.S.
PercentMM bpd
Country
USA Oil Imports USA Oil Imports –– The RiskThe Risk
•• 35 % from 35 % from politically volatilepolitically volatile(and potentially (and potentially volatile) areasvolatile) areas
2008 YTD 2008 YTD Oil Imports Oil Imports
(million barrels/day)(million barrels/day)CountryCountry
1.291.29MexicoMexico
1.531.53Saudi ArabiaSaudi Arabia
9.379.37……..TotalTotal
0.660.66IraqIraq
1.041.04NigeriaNigeria
1.151.15VenezuelaVenezuela
1.831.83CanadaCanada
Some US Energy Statistics• In 2006…
– consumed 139.9 billion gallons of gasoline– produced 3.9 billion gallons of ethanol
– consumed 43.2 billion gallons of diesel– produced 91 million gallons of biodiesel
– imported 65 percent of all petroleumSPREC – OSU
Ethanol as a FuelEthanol as a Fuel
Clean-burning, renewable fuel for vehicles
E10 (10% EtOH) is approved for most vehicles sold in the U.S.
Currently blended into about 46% of gasoline
SPREC – OSU
6.2 Billion gallons EtOH currently produced6.2 Billion gallons EtOH currently produced-- Over 134 plantsOver 134 plants-- 77 new plants under construction77 new plants under construction
Most ethanol made from cornMost ethanol made from corn-- Yield 2.7 gallons per bushelYield 2.7 gallons per bushel-- Uses ~20% of corn cropUses ~20% of corn crop
Currently No Commercial Cellulosic Plants in USACurrently No Commercial Cellulosic Plants in USASix proposed for Federal FundingSix proposed for Federal Funding
U.S. Ethanol ProductionU.S. Ethanol Production
SPREC – OSU
Current Ethanol Production Facilities Current Ethanol Production Facilities 134 operational, 77 under construction134 operational, 77 under construction
Ethanol Plant OwnershipEthanol Plant Ownership
•• Current PlantsCurrent Plants–– 47 percent of plants are farmer owned47 percent of plants are farmer owned
•• Plants under ConstructionPlants under Construction–– 12 percent of plants are farmer owned12 percent of plants are farmer owned
SPREC – Okla. State University
Potential ImpactPotential Impact50 MGY Ethanol Plant50 MGY Ethanol Plant
Employment requirements:Employment requirements:190190 Harvest Workers (9Harvest Workers (9--month)month)5050 Truck Drivers (12Truck Drivers (12--month)month)3030 Plant PersonnelPlant Personnel
270270 TotalTotal
Economic impact = $40 million per Economic impact = $40 million per yearyear
Some Biofuels StatisticsSome Biofuels Statistics•• 1 bushel of corn = 2.7 gallons of ethanol1 bushel of corn = 2.7 gallons of ethanol•• Corn Ethanol: 1.25 Corn Ethanol: 1.25 -- 1.33 to 1 energy ratio1.33 to 1 energy ratio
•• 1 ton of switchgrass = 60 to 80 gallons of ethanol1 ton of switchgrass = 60 to 80 gallons of ethanol•• Cellulosic Ethanol: 5 Cellulosic Ethanol: 5 –– 10 to 1 energy ratio 10 to 1 energy ratio
(depending on feedstock)(depending on feedstock)
•• 7.5 lbs of soybean oil = 1 gallon B1007.5 lbs of soybean oil = 1 gallon B100•• B100 has a 3.2 to 1 energy ratioB100 has a 3.2 to 1 energy ratio
SPREC – Okla. State University
What crop makes which fuel???What crop makes which fuel???•• EthanolEthanol
–– Corn starchCorn starch–– Cereal grains starchCereal grains starch–– Cellulosic materials (forestry products, Cellulosic materials (forestry products,
grasses, crop residues)grasses, crop residues)•• BiodieselBiodiesel
–– Oilseeds like soybean, rapeseed, canola, Oilseeds like soybean, rapeseed, canola, sunflowersunflower
–– Waste oilWaste oil SPREC – Okla. State University
Biodiesel OutlookBiodiesel Outlook
•• much better energy balance than ethanolmuch better energy balance than ethanol•• smaller, more dispersed conversion plantssmaller, more dispersed conversion plants•• higher feedstock costs as percent of inputhigher feedstock costs as percent of input•• less fuel specifications certainty and less fuel specifications certainty and
research than ethanolresearch than ethanol•• 1 to 3 years behind ethanol in consumer 1 to 3 years behind ethanol in consumer
acceptanceacceptance
SPREC – Okla. State University
Biodiesel StatisticsBiodiesel Statistics•• plants can be relatively smallplants can be relatively small•• cost about $1/gallon of capacitycost about $1/gallon of capacity•• full economies of scale at around 10 m full economies of scale at around 10 m
gallonsgallons•• currently about 395 m gallons of currently about 395 m gallons of
capacitycapacity•• 700 m gallons of new capacity under 700 m gallons of new capacity under
constructionconstruction SPREC – Okla. State University
Soybean Acres NeededSoybean Acres Needed•• If the majority of expansion uses If the majority of expansion uses
soybean oil:soybean oil:–– By 2011 we will need 4.5 million By 2011 we will need 4.5 million
additionaladditional acres of soybeans at trendacres of soybeans at trend--line line yieldsyields
–– SBO has competition from corn oil, white SBO has competition from corn oil, white or yellow grease, rapeseed, canolaor yellow grease, rapeseed, canola
SPREC – Okla. State University
Sugar Conversion
Ethanol Process
Sugars
ThermochemicalConversion
Syn-Gas
Ethanol (Fuel), Chemicals, Waste Products
GrassesStover and Straw
Sugar Cane Sweet Sorghum
Wood Products
Current Grain to Ethanol Current Grain to Ethanol Conversion TechnologyConversion Technology
Adopted from Adopted from C. Riley, NRELC. Riley, NREL
Ethanol
Grain
Corn Acres NeededCorn Acres Needed•• In order to maintain existing markets:In order to maintain existing markets:
–– by 2011, we will need 14 million by 2011, we will need 14 million additional additional corn acres at trendcorn acres at trend--line yieldsline yields
–– Expected ethanol production of 10 to 11 Expected ethanol production of 10 to 11 billion gallonsbillion gallons
–– Use of more than 10% of corn crop will Use of more than 10% of corn crop will impact food and feed pricesimpact food and feed prices
–– Currently using 20% of crop for ethanolCurrently using 20% of crop for ethanolSPREC – Okla. State University
Potential Crop Acreage ShiftPotential Crop Acreage Shift•• Corn BeltCorn Belt
–– soybeans and winter wheat to cornsoybeans and winter wheat to corn–– CRP will come back into productionCRP will come back into production
•• Great PlainsGreat Plains–– increase in corn and sorghumincrease in corn and sorghum–– decrease in small grainsdecrease in small grains–– increase in minor oilseedsincrease in minor oilseeds–– little change in soybeanslittle change in soybeans–– CRP will be reducedCRP will be reduced SPREC – Okla. State University
Conversion of Available FeedstocksConversion of Available Feedstocks
DOE DOE ““Billion TonBillion Ton”” study:study:Enough biomass to displace over 30% of Enough biomass to displace over 30% of current U.S. petroleum consumption, with current U.S. petroleum consumption, with no impacts to food, feed, or export no impacts to food, feed, or export demand.demand.
Will require a variety of biomass types:Will require a variety of biomass types:•• Dedicated energy cropsDedicated energy crops•• Forest landsForest lands•• Residue/wasteResidue/waste SPREC – Okla. State University
Ethanol Conversion TechnologiesEthanol Conversion Technologies
Adopted from Adopted from C. Riley, NRELC. Riley, NREL
Ethanol
Grain
Cellulosic Biomass
EmergingCurrent
Ethanol
GRASSoholGRASSGRASSoholoholUsing gasificationUsing gasification--fermentation fermentation
to convert biomass to fuelto convert biomass to fuel--grade ethanol grade ethanol
Biomass Potential from Crop Residue AloneBiomass Potential from Crop Residue Alone
•• Corn Belt Corn Belt –– 98.9 m tons 98.9 m tons –– (corn stover)(corn stover)•• Great Plains Great Plains –– 35.5 m tons 35.5 m tons –– (corn and (corn and
soybean stover, wheat, barley and oat soybean stover, wheat, barley and oat straw)straw)
•• West Coast West Coast –– 2.4 m tons 2.4 m tons –– (corn stover, (corn stover, wheat, barley and oat straw)wheat, barley and oat straw)
•• Delta Delta –– 4.6 m tons 4.6 m tons –– (rice straw)(rice straw)•• Southeast Southeast –– 3.6 m tons 3.6 m tons –– (sugarcane bi(sugarcane bi--
product)product) SPREC – Okla. State University
Barriers for Cellulosic EthanolBarriers for Cellulosic Ethanol•• Cost of production: $2.26/gal Cost of production: $2.26/gal (ORNL)(ORNL)
•• Large capital investment high riskLarge capital investment high risk•• Producer paradigm shiftProducer paradigm shift•• Lack of supply chain infrastructure, Lack of supply chain infrastructure,
industry standards, industry standards, regsregs..•• Consumer acceptance and awarenessConsumer acceptance and awareness•• High cost of harvest, handling, transport High cost of harvest, handling, transport
and storageand storage•• High feedstock variabilityHigh feedstock variability•• Unproven at commercial scaleUnproven at commercial scale
SPREC – Okla. State University
00 operationaloperational
6 plants proposed or under 6 plants proposed or under construcitonconstruciton
Current Cellulosic Ethanol Current Cellulosic Ethanol Production Facilities in the Production Facilities in the
U.S.U.S.
SPREC – Okla. State University
Biorefinery RequirementsBiorefinery Requirements•• Guaranteed consistent supply of high Guaranteed consistent supply of high
quality, low cost feedstockquality, low cost feedstock……365 365 days/yeardays/year
•• Cost must be LOW!!!!Cost must be LOW!!!!•• Quality must be consistentQuality must be consistent
–– Fermentation process depends on itFermentation process depends on it•• AVAILABILITY is essentialAVAILABILITY is essential
SPREC – Okla. State University
Conventional ProcessesConventional ProcessesCollectionCollection PackagingPackaging DeliveryDelivery
““ImprovedImproved”” Supply ModelSupply ModelProducerProducer
Country ElevatorCountry Elevator
DensificationDensification……ReductionReduction……ValueValue--Added ProcessAdded Process
““ProducerProducer”” Supply ModelSupply ModelProducerProducer DensificationDensification……
Chopped and modulesChopped and modules……Size ReductionSize Reduction……ValueValue--Added ProcessAdded Process
Eastern gamagrass
Indiangrass Bermudagrass
SwitchgrassSwitchgrass Traditional grasses with high production potential
SwitchgrassSwitchgrass
20 20
60 60DistributionDistribution
High biomass yield with High biomass yield with low inputlow input
Two types Two types Upland (5 Upland (5 –– 6 ft tall)6 ft tall)Lowland (10+ tall)Lowland (10+ tall)
Model herbaceous Model herbaceous species for development species for development as a bioenergy as a bioenergy feedstock cropfeedstock cropNative to N. America tall Native to N. America tall grass prairiesgrass prairies
Old World BluestemsOld World Bluestems
FlaccidgrassFlaccidgrass
“Exotic” grasses with high production potential
MiscanthusMiscanthus
Yield : Total Acres Yield : Total Acres 2 t/acre : 333,000 acre2 t/acre : 333,000 acre3 t/acre : 222,000 acre3 t/acre : 222,000 acre4 t/acre : 167,000 acre4 t/acre : 167,000 acre5 t/acre : 133,000 acre 5 t/acre : 133,000 acre
50 MGY Ethanol Plant50 MGY Ethanol Plant……Requires approximately 667,000 tons of Requires approximately 667,000 tons of
biomass per year (At 75 gal/ton)biomass per year (At 75 gal/ton)
SPREC – Okla. State University
More Options:More Options:Direct Fermentation of SugarsDirect Fermentation of Sugars(Sugarcane or Sweet Sorghum)(Sugarcane or Sweet Sorghum)
SPREC – Okla. State University
Ethanol Conversion TechnologiesEthanol Conversion Technologies
Ethanol
Grain SugarSugar
SPREC – Okla. State University
Sweet SorghumSweet Sorghum
•• High energy crop for ethanol High energy crop for ethanol production (15production (15--20% directly 20% directly fermentable sugar) fermentable sugar)
•• Can be grown in temperate climatesCan be grown in temperate climates
•• Low fertility requirements Low fertility requirements
•• Low water requirement: 1/2 corn and Low water requirement: 1/2 corn and 1/3 sugarcane1/3 sugarcane SPREC – Okla. State University
Sorganol Sorganol ®®
InIn--field harvesting, pressing, field harvesting, pressing, and fermenting sweet and fermenting sweet
sorghum juicesorghum juice
SPREC – Okla. State University
Traditional Sugar Processing
Sugarcane
Central FacilityOn-Farm
Press
Juice
Bagasse
Fermentation Distillation &Dehydration
Heat Energy
Potential In-Field Processing of Sweet Sorghum
Sorghum Press
Juice
Bagasse
Fermentation Distillation Dehydration
Central FacilityOn-Farm
Field Residue
Silage
Heat Energy
•• Develop biobased Develop biobased productsproducts
•• Stimulate economic Stimulate economic activityactivity
OKLAHOMABIOENERGY CENTER
Oklahoma Bioenergy Center Act
• Created the Oklahoma Bioenergy Center• $40 million over 4 years• Founding member institutions:
• Oklahoma State University• University of Oklahoma• The Samuel Roberts Noble Foundation
OKLAHOMABIOENERGY CENTER
Purpose of Center
The conduct of research and the delivery of practical outcomes to:
• Enable the competitive and sustainableproduction of liquid biofuels in Oklahoma, and
• Contribute to the national research effortto enable the United States to achieve prescribed levels of petroleum independence.
OKLAHOMABIOENERGY CENTER
Research Programs
• Primary research program• Outcomes: Sustainable, economic production of
cellulosic ethanol (or other high-value outputs)• Approach: Comprehensive, whole-system research
that integrates solutions from each stage of the biofuels production/value chain.
• Secondary research program• Outcomes: Critical elements in production of
biodiesel and ethanol from non-cellulosic sources
OKLAHOMABIOENERGY CENTER
Biofuels Value Chain
Oklahoma State UniversityUniversity of OklahomaThe Samuel Roberts Noble Foundation
Oklahoma Bioenergy Center
This might be YOU!
A New Day is InevitableA New Day is Inevitable
•• Producers MUST play a roleProducers MUST play a role•• There will be challengesThere will be challenges•• Is it time yet?Is it time yet?•• BE INVOLVED AND BE INVOLVED AND ……•• BE PREPAREDBE PREPARED
SPREC – Okla. State University
What can you do NOW?What can you do NOW?•• Keep updated on: Keep updated on:
–– Latest legislationLatest legislation–– Latest developments in productionLatest developments in production–– Latest developments of refinery locationsLatest developments of refinery locations
•• Be thinking about dual purpose Be thinking about dual purpose cropscrops……feed and feedstockfeed and feedstock
•• Be thinking about sustainability in your Be thinking about sustainability in your operationoperation
SPREC – Okla. State University